JP2015513631A - System and method for automatic optical inspection of industrial gas turbines and other generators having an articulated multi-axis inspection scope - Google Patents

Abstract

Internal components of the power generation machine, such as gas and steam turbines, automatically position the camera field of view (FOV) in a region of interest within the machine along a pre-specified navigation path and capture images without human intervention. Inspected using an optical camera inspection system capable. Automatic camera positioning and image capture is initiated automatically or after obtaining operator permission. The pre-designated navigation path is defined by the operator manually positioning the inspection scope within the generator or a similar generator of the same type. The navigation route may be defined by virtual simulation. The inspection system has an articulated multi-axis inspection scope.

Description

This application is entitled “Systems and Methods for Automatic Optical Inspection of Industrial Gas Turbines and Other Generators” filed on the same day as this application and assigned application number (13 / 362,417). Copending U.S. patent application filed with Attorney Docket No. US Patent Application 2011P28983US and “Automatic Optics for Industrial Gas Turbines and Other Generators with Articulated Multi-Axis Inspection Scope, filed on the same day as this application and assigned application number (13 / 362,352)” Co-pending US patent application entitled "System and Method for Inspection" And claims US patent application 2011P22742US, all of which are incorporated herein by reference.

  The present invention relates to an optical camera for non-destructive internal inspection of industrial gas turbines and other generators, including but not limited to steam turbines and generators. More specifically, the present invention relates to an optical camera inspection system that can automatically position a camera field of view (FOV) in an area of interest in a machine and capture images without human intervention. Automatic camera positioning and image capture is initiated automatically or after obtaining operator permission.

  Power generation machines such as steam or gas turbines are often operated continuously with periodic inspection and maintenance periods, when the turbine is removed from the line and shut down. As an example, gas turbine engines are often operated to generate electricity continuously for about 4000 hours, and soon afterwards they are lined up for maintenance of components identified during routine maintenance, inspection and inspection. Removed from. Removing a gas turbine from the line for scheduled maintenance and eventually shutting it down is a multi-day project. Some turbine components, such as the turbine rotor section, are operating at temperatures in excess of 1000 ° C. (1832 ° F.). In order to reduce the possibility of component warping or other deformation, the turbine achieves ambient temperature prior to complete shutdown requiring a cooling period of 48 hours to 72 hours. In order to reduce the possibility of the rotor warping during the stop phase, the turbine rotor is rotated in “gear rotation mode” by the auxiliary drive motor at about 10 RPM or less. Other turbine components, such as the turbine housing, are similarly gradually cooled to ambient temperature.

  Once the course of up to about 72 hours is completed and the turbine is cooled to ambient temperature, the currently stationary turbine internal components are inspected using an optical camera inspection system. Known optical camera inspection systems employ rigid or flexible optical borescopes that are inserted through inspection ports located around the periphery of the turbine. The borescope is manually positioned so that its field of view encompasses the region of interest within the turbine, such as one or more vanes or blades, combustor brackets, and the like. A camera optically coupled to the borescope captures an image of the object of interest in the field of view for remote visualization and (if necessary) archiving by the examiner.

  If a series of different images in different areas of interest within a given turbine inspection port is required, the operator manually repositions the borescope of the camera inspection system to the desired internal area and field of view. Relative alignment must be achieved. Relative alignment is achieved by physically moving the borescope so that its field port is located proximal to the region of interest that is stationary. Examples of such relative movement between the borescope and the static turbine component are by inserting the borescope in various directions within the static combustor or in the space between the blades or blade rows. By putting in or out of space. Relative alignment may also be accomplished by maintaining the borescope field of view port in a stationary position and operating the internal components of the turbine within the static field of view. An example of relative movement between the turbine internal components and the static borescope is the inspection of various blades in a blade row by continuously rotating the turbine rotor a small amount of angle and capturing images of the blades. is there. The rotor is continuously rotated to align each desired individual blade in the row within the camera's field of view.

  A complete turbine inspection requires multiple relative repositioning procedures between the view port of the camera inspection system and the area of interest in the turbine by a human inspector. Inspection quality and productivity are affected by inspection and operational skills of inspectors and inspection teams. Positioning the inspection device is difficult due to the complexity of the operating path between the components in the gas turbine. For example, inserting a borescope through the inspection port of the combustor to inspect the leading edge of the first row of vanes or associated support requires a complex operation. Incorrect positioning of the inspection device within the turbine can damage the internal components of the turbine. Inspection teams consisting of multiple operators often need to perform manual inspections using known inspection methods and equipment. That is, known manual camera inspection procedures and operation of the inspection system are time consuming, in fact repeated, and often require the assistance of a multi-person inspection team. “Human factors” required in known manual camera inspection procedures and inspection system operations lead to unnecessary inspection process discrepancies based on variations in human skill levels. In human skill mismatches, some inspection teams can complete the inspection in less time than others, achieve better image quality, and have a lower risk of inspection damage. The ideal skills of a high operational inspection team are recorded for use by all teams.

  In the art relating to optical camera inspection systems and methods, the total time required to perform a non-destructive internal inspection of a power generation machine, including, as a non-limiting example, a steam or gas turbine and a generator, with known inspection devices and methods. There is a need for being placed back in order to reduce power than is achieved and so to resume power generation more quickly during the maintenance cycle.

  In the art relating to optical camera inspection systems and methods, positioning an inspection device within a power generation machine, including, as a non-limiting example, a steam or gas turbine and a generator can be within a separate machine inspection cycle or inspection of a plurality of different machines. It is possible to consistently and repeatably in the cycle, minimizes the risk of damage to the internal components of the machine, achieves higher image quality and inspection cycle time than can be achieved with known inspection devices and methods There is another need for being quick.

  There is yet another need in the art relating to optical camera inspection systems and methods to help average inspection skill levels and productivity among various inspection teams.

  Accordingly, a possible object of the present invention is an optical inspection system and method for a power generation machine (including, as a non-limiting example, a steam or gas turbine and a generator), combined with other objects or individually. This optical inspection system and method reduces the overall periodic maintenance period compared to known inspection instruments and methods, and within the inspection cycle of individual machines or of different machines. Position inspection instruments consistently and repeatedly within the inspection cycle, minimizing the risk of damage to internal machine components and high image quality, and homogenizing inspection skill levels and productivity across various inspection teams To help.

  Internal components of the power generation machine, such as gas and steam turbines or generators, are inspected using an optical camera inspection system, which follows a pre-specified navigation path to an area of interest within the machine. It is possible to automatically position the camera field of view (FOV) and capture images without human intervention. Automatic camera positioning and image capture is initiated automatically or with the permission of the operator. The pre-specified navigation path is defined by the operator manually positioning the inspection scope in the generator machine or similar generator machine of the same type and recording a sequence of positioning steps for future iterations.

  These and other objects are achieved in accordance with the present invention by a system for internal inspection of a gas or steam turbine. The system has a substrate for attachment to a turbine inspection port. The system also has an inspection scope having an elongate elongate body having a proximal end rotatably coupled to the base and a distal end for insertion into the turbine inspection port. The inspection scope has an elongated portion in the middle between the proximal end portion and the distal end portion, and first and second joint end portions on the opposite sides, and the first joint end portion is connected to the distal end portion of the inspection scope. And an articulated joint. A camera head having a field of view is connected to the second joint end of the joint joint. The whole rotation drive body is connected to the inspection scope for rotating the inspection scope around the central axis of the inspection scope. The scope extension driver is coupled to the extension portion to translate the extension. The joint driver is coupled to the camera head to articulate the field of view of the camera head with respect to the central axis of the inspection scope. The camera is connected to the camera head to capture an image in the field of view. The system also has a control system that automatically positions the inspection scope and field of view to the internal area of interest along a pre-specified navigation path in the turbine and human In order to capture camera images without intervention, it is connected to a global rotation drive, scope extension drive, joint drive and camera.

The invention also features a system for internal inspection of a steam or gas turbine, the system having a substrate for attachment to a gas turbine inspection port. The system also has an elongate elongate body having a proximal end rotatably coupled to the base and a distal end for insertion into the turbine inspection port and defining a central axis.
The elongated portion is intermediate between the proximal end portion and the distal end portion. The inspection scope has first and second articulation joints on opposite sides, and has an articulation joint with a first joint end connected to the distal end of the inspection scope. The camera head extension is connected to the second end of the joint joint. The extension has a camera head nesting portion and a camera head rotation / pan joint coupled to the second end of the articulation joint. The inspection scope has a field of view and has a camera head coupled to a camera head extension and a camera head rotation / pan joint. The inspection scope has a driver for the movement axis. The whole rotation driving body rotates the inspection scope around its central axis. The scope extension driver translates the extension part, and the joint driver articulates the field of view of the camera head relative to the central axis of the inspection scope. The camera head extension driver translates the camera head nest, and the camera head rotation / pan driver rotates the camera head. The camera is coupled to the camera head for capturing an image in the scope field of view. The control system provides a global rotary drive for automatically positioning the inspection scope and field of view along the pre-specified navigation path in the turbine to an internal area of interest and for capturing camera images without human intervention. , A scope extension driver, a joint driver, a camera head extension driver, a camera head rotation / pan driver, and a camera.

  The present invention also features a method for internally inspecting a steam or gas turbine and includes providing an internal inspection system. The inspection system has a base for attachment to the turbine inspection port and an inspection scope coupled to the base. More particularly, the inspection scope has an elongate elongate body defining a central axis and having a proximal end rotatably coupled to the base and a distal end for insertion into the turbine inspection port. The inspection scope has an elongated portion in the middle between the proximal end portion and the distal end portion, and first and second joint end portions on opposite sides, and the first joint end portion is connected to the distal end portion of the inspection scope. And an articulated joint. A camera head having a field of view is connected to the second joint end of the joint joint. The inspection scope also has a plurality of drivers for imparting selective movement to the scope. The whole rotation driving body rotates the inspection scope around its central axis. The scope extension driver translates the extension part. The joint driver jointly moves the visual field of the camera head with respect to the central axis of the inspection scope. The camera is coupled to the camera head to capture an image in the inspection scope field of view. The system uses a global rotary drive, scope extension to position the inspection scope and field of view along a pre-specified navigation path in the turbine to an internal area of interest and to capture its camera image without human intervention. A control system coupled to the driver and joint driver and the camera; The inspection method is further performed by attaching a substrate to the turbine inspection port. A navigation path is provided to the control system. The turbine is inspected using the control system by automatically positioning the inspection scope and camera head field of view along the navigation path and capturing the camera image without human intervention.

  The navigation path is pre-specified by several methods and is recorded for future iterations by the actual inspection scope control system used in the inspection step. The method of pre-designating the navigation path is the inspection step in the gas turbine that is actually inspected (or in another gas turbine having the same type of internal structure as the gas turbine that is actually inspected) along the selected navigation path. The type of inspection that was used during the inspection step within the type of virtual generator that is to be inspected along the selected navigation path, with the human being previously controlling and positioning the type of inspection scope used during Simulate positioning of virtual scopes and virtual generators of the type used in the inspection step according to simulated selected navigation without human intervention and positioning of the scope in a simulated manner Positioning.

  The objects and features of the invention may be applied in combination or individually in any combination or sub-combination by those skilled in the art.

  The teachings of the present invention can be quickly understood by considering the following detailed description in conjunction with the accompanying drawings, in which:

1 is a schematic partial cross-sectional view showing a known gas turbine. 1 is a schematic partial cross-sectional view illustrating a known gas turbine, and is a schematic partial cross-sectional view illustrating partially inserting an optical camera inspection system according to an embodiment of the present invention into an inspection port of a combustor. . FIG. 3 is a schematic partial cross-sectional view showing a known gas turbine, and is a schematic partial cross-sectional view for performing inspection of internal components of a combustor using the optical camera inspection system shown in FIG. 2. FIG. 3 is a schematic partial cross-sectional view illustrating a known gas turbine, wherein the optical camera inspection system illustrated in FIG. 2 is used to perform an inspection at the leading edge of the turbine blades in row 1. FIG. 3 is a schematic perspective view showing the optical camera inspection system according to the embodiment of FIG. FIG. 6 is a schematic perspective view showing the optical camera inspection system of FIG. 5 at the folding inspection position of FIG. 2. FIG. 6 is a schematic perspective view showing the optical camera inspection system of FIG. 5 in the lock inspection position of FIG. 3. It is a schematic perspective view which shows the expansion | extension pipe | tube mechanism part of the optical camera inspection system of FIG. It is a schematic perspective view which shows the adapter ring of this invention attached to the inspection port of a turbine. FIG. 6 is a schematic front view showing a camera head joint movement and rotation (pan) mechanism of the optical camera inspection system of FIG. 5, and shows a schematic front view showing degrees of motion Φ and Θ. It is a schematic plan view which shows the camera head joint movement and rotation (pan) mechanism of FIG. FIG. 6 is a schematic front view showing a camera head extension mechanism of the optical camera inspection system of FIG. 5 and showing a degree of mobility. It is a schematic perspective view which shows the camera head of the optical camera inspection system of FIG. FIG. 6 is a schematic exploded perspective view showing a camera head of the optical camera inspection system of FIG. 5. It is a general | schematic partial assembly perspective view which shows the camera head of FIG. 6 is a block diagram illustrating a control box and control system for the optical camera inspection system of FIG. 1 is a schematic perspective view showing a tablet computer-type human machine interface (HMI) according to an embodiment for allowing an operator to remotely observe and control the optical camera inspection system of the present invention. FIG. 1 is a schematic partial cross-section illustrating a known gas turbine, showing a partial optical cross-section showing another optical camera inspection system of an embodiment of the present invention inserted into two separate turbine section rows of each inspection port. FIG. It is a front perspective view which shows the optical camera test | inspection system of embodiment of FIG. 18, Comprising: It is a front perspective view which shows the degree-of-motion Τ, Θ, and Φ obtained. It is a front view which shows the rocking | fluctuation prism joint mechanism for the mobility (PHI).

  For ease of understanding, the same reference numerals are used as necessary to determine the same elements common to the figures.

  After considering the following description, those skilled in the art will readily use the teachings of the present invention in an optical camera inspection system for non-destructive internal inspection of power generation machines including steam or gas turbines and generators as non-limiting examples. Clearly understand that The optical camera inspection system can automatically position the camera field of view (FOV) in an area of interest within the machine and capture images without human intervention. Automatically positioning the camera and capturing the image is started automatically or after obtaining the operator's permission. Alternatively, the system may be operated manually in “manual” mode.

Camera Inspection System Overview Referring to FIG. 1, an embodiment of the present invention facilitates automatic off-line remote visual inspection of internal components of a gas turbine 30, which includes combustor 34, row 1 of turbine sections. And row 2 stationary vanes 42, 46, leading row 1 and row 2 rotating blades 44, 48, and ring segments. As shown in FIGS. 2-4 and 18, an inspection system according to an embodiment of the present invention is achieved by attaching remotely operated optical camera inspection scope probes 60, 220 to turbine inspection ports 36, 50 and 52. Allows inspection of off-line turbines that are not fully cooled to ambient temperature. When installed, the inspection scope probes 60, 220 are selectively positioned via an internal motion control servomotor (automatically by an operator or automatically without an operator) under the command of the motion control system. Image data is acquired, captured, and archived for further analysis as needed.

Articulated Inspection Scope FIGS. 2-4 illustrate inspection of a gas turbine by inserting an articulating inspection scope 60 of one embodiment into the inspection port 36 of the combustor 34 (FIG. 2). In order to steer the distance of the scope 60 around the boundary of the gas turbine equipment, the inspection scope 60 has a foldable knuckle joint so that if the scope is an elongated scope, it will halve to an approximately L-shaped profile in half. Folded. Once the scope 60 is positioned in the inspection port 36, the knuckle joint is straightened as shown in FIG. After attaching inspection scope 60 to inspection port 36, the scope is used to inspect the internal components of the combustor by rotating and extending its camera head. In FIG. 4, since the scope 60 is further extended and its camera head is articulated, images of the leading edge of the blades in row 1 and the blades in row 1 are acquired. When the turbine rotor is in rotational mode, images of all blades in row 1 are captured as they rotate past the camera head field of view.

Referring to FIG. 5, the inspection scope 60 includes three main component sections, an elongated tubular section 62 (see FIGS. 5-9), a motor jacket 64 (FIGS. 5 and 10-12), and a camera tip 66 ( 5 and 12 to 15), which can carry out the following five degrees of freedom of movement.
Ω-total rotation Τ-telescopic extension Φ-joint movement of camera head Ε-extension of camera head tip θ-rotation / panning of camera head

  The elongate tubular section 62 has a mounting tube 70 and a mounting collar 72 that is attached to an inspection port, such as the combustor inspection port 36. The motor housing 74 is attached to the opposite end of the attachment tube body 70 on the distal end side of the attachment collar body 72, and accommodates a servo motor necessary for executing the motility Ω and wrinkles. Three telescoping tubes 75-77 sink into the mounting tube 70 to provide heel motion.

  As shown in FIGS. 6 and 7, the spring loaded lock knuckle joint 80 allows the entire inspection scope 60 to be folded for miniaturized maneuvering with respect to the turbine 30 as shown in FIG. 2 and described above. To do. The lock sleeve 77A slides over the telescoping tube 77 and restrains the knuckle joint 80 there when the inspection scope 60 is in the lock inspection position as shown in FIG.

  As shown in FIG. 5, the motor covering 64 houses the servomotor necessary to position the motor-driven articulation joint 82, which has a degree of motion Φ and a telescoping extension 84 of the camera head. , 86 and the rotation / panning motion Θ of the camera head 88. The camera head 88 has camera ports 90 and 92 for axial and lateral fields of view (FOV), respectively.

  FIG. 8 is a detailed view of the motor housing 74, showing the large and small diameter gears within the rotating hub 100, two coaxially nested and independently driven. The rotary drive gear 102 is driven by a rotary servo motor 104 in order to generate Ω motion by the rotation of the large diameter gear in the rotary hub 100. The telescopic extension drive screw 106 is firmly coupled to a small diameter gear in the rotating hub 100 and in turn engages with the extension drive gear 108. The extension servo motor 110 is involved in generating a saddle movement by rotating a small-diameter gear in the rotary hub 100. The mounting collar 72 is attached to the adapter ring 112 and in turn is attached to an inspection port, such as the inspection port 36 of the combustor. As shown in FIG. 9, the adapter ring has a plurality of outer threads 114 that are engaged with a pair of inner threads in the collar body 72. The adapter ring 112 has a mounting hole 116 for receiving a tapered head machine screw 118. The screw 118 is attached to be anchored in the adapter ring 112. Other structures of the adapter ring 112 and other shapes of the base that attaches the scope to the inspection port may be replaced.

  Referring to FIG. 10, the motor cover 64 has a motor cover housing 120 having a pair of spaced ear-shaped motor cover rotation shafts 122. The joint motion servo motor 124 rotates the drive screw 126 that imparts the joint motion Φ by tilting the camera turning hub 128. The tilting movement shaft 132 is formed between the camera hub turning shaft 130 that is rotatably connected to the motor cover turning shaft 122. The offset link 133 is connected to the drive screw 126 and converts linear motion into rotational motion around the tilt motion axis 132.

  Similarly, the motor casing 120 houses a camera pan / rotation servo motor 134 that imparts Θ motility to the camera head 66, as shown in FIG. Servo motor 134 drives bevel gear train 136, which in turn has a drive bevel gear that is rotatably captured within camera pivot hub 128 to similarly rotate rotating hub 129. . The rotating hub 129 is securely connected to the camera head telescopic extension 84. The camera tip telescopic extension bodies 84 and 86 are extended and retracted by the extension servomotor 140 with a degree of motion, and the extension servomotors are in turn engaged with the linear drive screw 142. The drive screw 142 has a drive pulley 144 that passes through a tensioned cable 146. The sub pulley 148 is attached to the camera head 88 and is similarly connected to the cable 146. The coil spring 150 is interposed between the camera head 88 and the rotating hub 129 and biases them away from each other, thereby applying tension to the cable 146. As a result, selectively moving the drive screw 142 by the extension servo motor 140 causes the camera head 88 to move left and right (movement rod) in the drawing.

  FIGS. 13-15 show a camera head 88 having a bivalve structure with a camera head housing 152 and a selectively removable cover 15. The camera 156 has a field of view (FOV) through a “camera 1” port 90 that extends along the central axis of the camera head 88. Camera 158 has a field of view (FOV) through “Camera 2” port 92 that is transverse or perpendicular to the central axis of camera head 88. Camera 156 generates the image through prism 160. Cameras 156 and 158 are known autofocus USB cameras of the type normally used on personal computers. Light emitting diodes (LEDs) 162 and 164 provide illumination to cameras 156, 158 during internal inspection of the power machine.

  As schematically shown in FIG. 15, the inspection scope 60 is cooled from the outside by a cooling air line 170 and a pressurized cooling air source 172 (for example, compressed air). Cooling air passes through the scope 60 and transfers heat away from the instrument, and the cooling air is in scopes such as camera ports 90 and 92 around the cameras 156 and 158 and LEDs 162 and 164, prism 160. Drain through the gap on the outer surface. These gaps effectively function as cooling air exhaust ports. Cooling air exhausted from the various cooling ports assists in transferring heat from the scope 60 and creates a thermal barrier around the camera head 88 that is relatively cooler than the internal temperature of the turbine 30 that is not fully cooled. To help form. In this manner, the inspection scope 60 can be inserted into a turbine that is still hot when shut down, but for several hours before the turbine cools to ambient air temperature. In this way, the inspection can be started hours or even days earlier than allowed by known inspection systems. In this way, the inspection process can be started and completed earlier in the service life of the turbine than previously possible, and in some cases reduces the total maintenance cycle period.

Control and Operation of Camera Inspection Scope Positioning the inspection scope 60 along its five degrees of motion is the same as the five precision motion control servo motors 104 (Ω), 110 (Τ), 124 (Θ), 124 (Φ ) And 140 (Ε). The servo motor has an associated encoder that provides feedback of motor position information for use by a controller of a known motion control system. FIG. 16 is a block diagram illustrating an exemplary motion control system of the present invention. The hardware of the inspection scope 60 described above is indicated by a broken line 60 and communicates with a control box 180 similarly indicated by a broken line using a known communication path such as a multipath cable 192 and a USB camera cable.

  The control box 180 has first and second power sources 182, 184 for the motion controller 186 and the motion controller motor driver 188. All of the components 182-188 are of known design used in industrial motion control systems. The motion controller 186 applies a voltage to the servo motors 104 (Ω), 110 (Τ), 124 (Θ), 124 (Φ), and 140 (Ε) of the inspection scope 60 and reverses the motion control motor drive. Commands are given to the body 188. For brevity, all such motors are collectively referred to as “servo motors”. Each servo motor has an associated encoder that generates an encoder signal indicating the scope position in each of its range of motion. For example, an encoder associated with the servo motor 104 generates a rotational position signal that indicates the overall rotational position (Ω) of the elongated tubular portion 62. Position signal information from each encoder is accessed by the motion controller 186. The motion controller 186 correlates the motor encoder signal with the spatial position of the inspection scope 60. The digital light controller 190 controls the illumination output and on / off of the LEDs 162 and 164 and communicates with the motion controller 186. The motion controller 186 similarly controls the cooling air to and through the inspection scope 60, such as the flow rate exiting the cooling port 174, for example.

  The exercise controller 186 has an optional wireless communication function 194. A wired data path 198 such as a cable for transmitting a communication signal conforming to the Ethernet (registered trademark) protocol communicates with the host controller 200. The exemplary host controller 200 is a personal computer having an internal memory function and, optionally, an external memory 202. Similarly, the host controller 200 receives and processes image data to be processed from the camera 156 (USB camera 1) and from the camera 158 (USB camera 2). The computer 200 archives or otherwise stores the processed or processed image data in the memory 202. The inspection scope 60 may be positioned under human command or control, for example via the joystick 204 and / or the HMI vision / touch screen 206. Optionally, the computer 200 may have a wireless communication function to communicate with other computers including, for example, a tablet computer having an HMI. FIG. 17 shows an exemplary tablet computer including an image display unit 212 of the camera 1, an image display unit 214 of the camera 2, a probe position information display unit 216, and an HMI control interface 218 for operating the position of the inspection scope 60. 2 shows an HMI display screen. The tablet computer 210 may have a direct communication function with the motion controller 186 that does not need to communicate via the host controller computer 200.

Blade / Vane Inspection Scope A blade / blade inspection scope 220 according to an embodiment is shown in FIGS. This embodiment is particularly suitable for inspecting the boundaries of the turbine section 38 of the gas turbine 30 between rows of rotating blades and stationary vanes. FIG. 18 shows a pair of inspection scopes 220 each attached to each of the inspection port 50 in row 1 and the inspection port 52 in row 2. However, at the discretion of the inspection team, a single inspection scope 220 may be attached to the selected inspection port, or more than two inspection scopes 220 may be attached to the turbine 30 simultaneously during the inspection procedure. Similarly, at its discretion, the inspection team may operate one or more inspection scope 60 embodiments simultaneously with or without inspection scope 220 embodiments in any inspection procedure.

  As shown in FIGS. 19 and 20, the inspection scope 220 according to the embodiment is attached to an inspection port of the gas turbine (here, the inspection port 50 in the row 1) by a mounting flange 222. A linear driver 224 having an associated servo motor and encoder translates the inspection scope in a telescoping extended position momentum. A rotary driver 226 with associated servo motors and encoders rotates the inspection scope at camera rotation / pan motion Θ. The borescope 228 is mechanically coupled to the linear driver 224 and the rotary driver 226 and has a camera head 230 that captures within its field of view (FOV). The camera head 230 has a swivel prism 232, and the movement of this swivel prism at the articulation degree Φ is provided by an associated servo motor and encoder. The borescope 228 has a known configuration and includes a fiber optic lens 234 and auxiliary external illumination (not shown) that illuminates and transmits an image in the field of view of the camera head to the camera 236. The camera 236 may be an autofocus USB camera coupled to a motion control system as shown in FIG. The overall motion control and positioning of the inspection scope 220 along its degrees of motion Φ, Θ, and Τ and camera image capture are performed as described above with respect to the embodiment of the inspection scope 60.

  Inspection scope 220 has an external cooling system for inspection during the cooling phase of turbine 30 where the temperature of turbine section 30 is still rising to a maximum of about 150 ° C. As described in connection with the embodiment of the inspection scope 60, the cooling system has an air line 170 that extends parallel to or into the bore scope 228, which is derived from a cooling air source. The cooled air is discharged through one or more functional cooling air outlets around the camera head 230, for example.

  The three degrees of motion Φ, Θ, and に お け る in the blade / blade inspection scope 220 according to the embodiment are the leading or trailing edges of all rotating turbine blades in a given row while the turbine rotor is rotating in the rotating gear mode. It is enough to get a complete image of the end side. For example, in FIG. 18, the tip side of each turbine blade 44 in row 1 is inspected by an inspection scope 220 positioned at inspection port 50. As each individual blade rotates within the field of view of the camera head 230, its image is captured by the associated control system. Some or all of the series of blade images are obtained during rotation of a single rotor 40 while the turbine 30 is in the rotating gear mode. The field of view of a single camera head 230 may not capture the entire radial length in the region of interest of the turbine blade. By repositioning the tilt angle Φ of the camera head, or by inserting / retracting the borescope 228 along the degree of freedom Τ, the camera field of view is again radiated along the length of the blade or vane. Positioned. The images captured at different blade / blade radial positions are combined to form a collective image of the entire blade. Similarly, an image of the trailing edge of each blade 44 in row 1 may be captured by positioning the inspection scope 220 at the turbine inspection port 52 as was done for the leading edge.

Exemplary Turbine Inspection Procedure The camera inspection system of the present invention provides the ability to automatically locate and capture the inspection camera field of view in an area of interest in a turbine, such as a gas turbine, without human intervention. To do. After providing the system with sequence information to locate the inspection scope, subsequent inspections can be repeated by different inspection teams regardless of the specific skill or inspection speed of positioning the inspection scope in the inspection team. Automated inspection completes quickly compared to known inspection procedures and is less prone to human error. Further description of the inspection method of the present invention will be made with reference to the inspection of an exemplary industrial gas turbine.

  Inspection scope positioning sequence information is obtained by placing an inspection scope according to an embodiment of the present invention at a selected inspection port and directing all controlled movements to an initialization or “start” position. The human inspector guides the inspection scope through the HMI of the control system. A human inspector may, for example, by means of a joystick or touch screen pad, via the control system's HMI, through the navigation path in the turbine recorded in one or both of the controller / host computer of the control system. To guide you. The navigation path is selected to direct the field of view of the inspection scope camera head within the region of interest without causing undesired impact of the scope with internal components of the turbine.

  The control system can maintain the navigation path from the initial human-controlled inspection and subsequently repeat the inspection scope positioning sequence for future inspection cycles for the same turbine or other turbines having the same internal structure. For example, a navigation path sequence may be performed on a single test turbine, and the sequence communicates to other remote locations for use by an inspection team inspecting the same structure gas turbine at the site. May be. In the field, inspection teams may be concerned that different gas turbines may vary in internal structure from the original gas turbine. The field team may review the recorded navigation paths individually, step by step, using local overrides that perform inspections to meet the required path variations for turbines installed in the field, or on-site A new navigation path targeted to a turbine may be selected to be programmed.

  Alternatively, the navigation path is determined in virtual space by simulating a navigation path in the turbine simulated by a human inspector and recording this path for later use in an inspection in the actual turbine. As another alternative, the scope inspection simulation program prepares the proposed inspection navigation path for review and approval by a human inspector.

  The navigation path sequence moves the camera head field of view from one position of interest to another position of interest. For example, as soon as the inspection scope is attached to the combustor inspection port, the inspection system captures and records an image of the internal components within the combustor and moves to the leading edge of the row 1 blade. Pass the blades and inspect the leading edge of the blades in row 1. When the turbine is in the rotating gear mode, the camera head continuously records the same image for each blade during a single rotor rotation.

  When in the navigation path position, the camera head may be repositioned from the same reference point to obtain image information from different camera views. Various images acquired from the same reference point may be combined to obtain a composite or “stitched” structural element diagram, or a virtual “patrolling” of any or all parts inside the turbine ( tour) ".

  Rather than moving the inspection scope camera head field of view from one position to another, the region of interest of the turbine component may be moved within the static camera head field of view. For example, whether the turbine is in rotating gear mode, or whether the operator manually hits each blade continuously in front of the camera head with a fully stopped turbine rotor between blades and blade rows. The inspection scope inserted in can capture an image of each blade rotating within the camera's field of view.

  While various embodiments have been shown and described herein that incorporate the teachings of the present invention, those skilled in the art can readily devise numerous other variations that still incorporate these teachings. For example, an “optical image” of the internal components of the turbine may be obtained in the visible light spectrum or in the infrared spectrum. The mobility of the inspection scope need not be limited to these exemplary movements enabled by servo motors 104 (Ω), 110 (Τ), 124 (Θ), 124 (Φ), and 140 (Ε). The movement of the scope need not be imparted by a servo motor, but may have another known pneumatic or other motion control system.

30 Gas Turbine, Turbine Section, Turbine, 34 Combustor, 36 Inspection Port, 36, 50 Turbine Inspection Port, 38 Turbine Section, 40 Rotor, 42, 46 Fixed Blade, 44, 48 Turbine Blade, Blade, 50, 52 Turbine Inspection port, inspection port, 60, 220 Optical camera inspection scope probe, inspection scope probe, blade inspection scope, articulated inspection scope, inspection scope, scope, 62 elongate tubular part, elongate tubular section, 66 camera tip, camera head, 75 -77 Nested tube, 80 Spring-loaded lock knuckle joint, knuckle joint, 82 articulated joint, 84, 86 Camera head telescopic extension, Camera tip telescopic extension, 88, 230 Camera head, 156, 158, 236 turtle , 188 motion controller motor driver, motion control motor driver, 224 linear drive member, 226 rotary drive member

Claims (20)

A system for internal inspection of a turbine,
A substrate for attachment to the turbine inspection port;
An inspection scope having a proximal end rotatably coupled to the base and a distal end for insertion into the turbine inspection port, and an elongate elongated body defining a central axis; An extension portion in the middle of the base end portion and the distal end portion; and first and second joint end portions on opposite sides; and the first joint end portion is coupled to the distal end portion of the inspection scope. An inspection scope having a joint joint;
A camera head having a field of view and coupled to the second joint end of the joint joint;
An overall rotation driving body for rotating the inspection scope around the central axis of the inspection scope, the entire rotation driving body coupled to the inspection scope;
A scope extension driver for translating the extension part, the scope extension driver coupled to the extension part;
A joint driver for articulating the visual field of the camera head with respect to the central axis of the inspection scope, the joint driver being coupled to the camera head;
A camera coupled to the camera head for capturing an image in a field of view;
A control system coupled to the overall rotation drive, the scope extension drive and the joint drive and the camera, wherein the inspection scope and field of view are of interest along a pre-specified navigation path in the turbine. A control system for automatically positioning in an area and for capturing a camera image of the camera without human intervention;
A system comprising:   The system of claim 1, wherein the control system automatically and continuously positions the field of view into a plurality of regions of interest and captures each image of the region of interest. Combining images of multiple areas of interest
Combining images from multiple areas of interest to generate a composite image;
Combining images captured multiple times and overlaying the images,
The system according to claim 2, wherein a composite image including a composite image selected from the group consisting of:   The system of claim 1, further comprising a cooling system coupled to the inspection scope for routing pressurized cooling gas through the inspection scope.   The system of claim 1, further comprising an illumination system coupled to the camera head, the illumination system illuminating to illuminate a field of view of the camera head. The navigation route designation is
A human controls and positions the inspection system within the same type of turbine along the selected navigation path and records the navigation path for subsequent iterations by the inspection scope control system;
Along the selected navigation path, a human controlled and simulated positioning of the virtual inspection system within the same type of virtual turbine and recording the navigation path for subsequent iterations by the inspection scope control system;
Simulating positioning of the same type of virtual inspection scope and virtual generator along the simulated selected navigation path without human intervention and recording the navigation path for subsequent iterations by the inspection scope control system;
The system of claim 1, wherein the system is selected from the group consisting of: The turbine is a gas turbine;
The substrate is coupled to a combustor inspection port;
The system of claim 1, wherein the captured image is selected from the group consisting of an internal component of a combustor section, an internal component of a turbine section, row 1 vanes, and row 1 blades. A first camera coupled to the camera head, the first camera capable of capturing an image in a first field of view substantially parallel to a central axis of the camera head;
A second camera coupled to the camera head, wherein the second camera is capable of capturing an image in a second field of view that is aligned substantially laterally with respect to the central axis of the camera head. When,
The system of claim 1, further comprising:   A camera head extension between the second joint end of the articulation joint and the camera head, the camera head nesting part, connected to the camera head and to the control system, the camera head nesting part A camera head extension body having a camera head extension driver for translating, so that the control system can translate the camera head extension body when positioned in the field of view. The system according to claim 1.   A camera head rotation / pan joint intermediate between the second joint end of the joint joint and the camera head, the camera being coupled to the camera head and to the control system for rotating the camera head A camera head rotation / pan joint having a head rotation / pan driver is further provided, so that the control system is capable of rotating / panning the camera head when positioned in the field of view. Item 4. The system according to Item 1.   The system of claim 1, further comprising a knuckle joint intermediate the proximal and distal ends of the inspection scope for selectively folding the inspection scope. A system for internal inspection of a gas turbine,
A substrate for attachment to the gas turbine inspection port;
An inspection scope having a proximal end rotatably coupled to the base and a distal end for insertion into the turbine inspection port, and an elongate elongated body defining a central axis; An extension portion in the middle of the base end portion and the distal end portion; and first and second joint end portions on opposite sides; and the first joint end portion is coupled to the distal end portion of the inspection scope. An articulated joint; a camera head extension coupled to the second joint end of the joint joint and having a camera head nesting portion; and a camera head rotation / coupled to the second joint end of the joint joint. An inspection scope having a pan joint;
A camera head having a field of view and coupled to the camera head extension and the camera head rotation / pan joint;
An overall rotation driving body for rotating the inspection scope around the central axis of the inspection scope, the entire rotation driving body coupled to the inspection scope;
A scope extension driver for translating the extension part, the scope extension driver coupled to the extension part;
A joint driver for articulating the visual field of the camera head with respect to the central axis of the inspection scope, the joint driver being coupled to the camera head;
A camera head extension driver for translating the camera head nesting part, wherein the camera head extension driver is connected to the camera head nesting part;
A camera head rotation / pan drive for rotating the camera head, the camera head rotation / pan drive coupled to the camera head;
A camera coupled to the camera head for capturing an image in a field of view;
A control system connected to the entire rotation driving body, the scope extension driving body, the joint driving body, the camera head extension body, the camera head rotation / pan driving body, and the camera; A control system for automatically positioning to an internal area of interest along a pre-specified navigation path in the turbine and for capturing a camera image of the camera without human intervention;
A system comprising: A cooling system coupled to the inspection scope, the cooling system for routing pressurized cooling gas through the inspection scope and the camera head;
An illumination system coupled to the camera head to illuminate a field of view of the camera head;
A first camera coupled to the camera head, the first camera capable of capturing an image in a first field of view substantially parallel to a central axis of the camera head;
A second camera coupled to the camera head, wherein the second camera is capable of capturing an image in a second field of view that is aligned substantially laterally with respect to the central axis of the camera head. When,
The system of claim 12, further comprising: A method for inspecting a turbine internally,
Preparing an internal inspection system, the internal inspection system comprising:
A substrate for attachment to the turbine inspection port;
An inspection scope having a proximal end rotatably coupled to the base and a distal end for insertion into the turbine inspection port, and an elongate elongated body defining a central axis; An extension portion in the middle of the base end portion and the distal end portion; and first and second joint end portions on opposite sides; and the first joint end portion is coupled to the distal end portion of the inspection scope. An inspection scope having a joint joint;
A camera head having a field of view and coupled to the second joint end of the joint joint;
An overall rotation driving body for rotating the inspection scope around the central axis of the inspection scope, the entire rotation driving body coupled to the inspection scope;
A scope extension driver for translating the extension part, the scope extension driver coupled to the extension part;
A joint driver for articulating the visual field of the camera head with respect to the central axis of the inspection scope, the joint driver being coupled to the camera head;
A camera coupled to the camera head for capturing an image in a field of view;
A control system coupled to the overall rotation drive, the scope extension drive and the joint drive and the camera, wherein the inspection scope and field of view are of interest along a pre-specified navigation path in the turbine. A control system for automatically positioning in an area and for capturing a camera image of the camera without human intervention;
Having a step;
Providing the navigation path to the control system;
Using the control system to inspect the turbine by automatically positioning the inspection scope and the camera head field of view along the navigation path and capturing a camera image of the field of view without human intervention;
A method comprising the steps of: In the internal inspection system,
A camera head extension between the second end of the articulation joint and the camera head, the camera head nesting part, connected to the camera head and to the control system, the camera head nesting part A camera head extension drive for translating, so that the control system can translate the camera head extension when positioned in the field of view;
A camera head rotation / pan joint intermediate between the second joint end of the joint joint and the camera head, the camera being coupled to the camera head and to the control system for rotating the camera head A camera head rotation / pan joint having a head rotation / pan driver so that the control system can rotate / pan the camera head when positioned in the field of view;
15. The method of claim 14, further comprising the step of: In the internal inspection system,
A first camera coupled to the camera head, the first camera capable of capturing an image in a first field of view substantially parallel to a central axis of the camera head;
A second camera coupled to the camera head, wherein the second camera is capable of capturing an image in a second field of view that is aligned substantially laterally with respect to the central axis of the camera head. When,
Providing a step;
Capturing camera images from both the first and second cameras without human intervention;
The method of claim 14, further comprising:   During the inspection step, the control system automatically and sequentially positions the camera field of view along the navigation path to a plurality of regions of interest by moving the inspection scope, The method according to claim 14, further comprising capturing a plurality of images. Combining images from multiple areas of interest to generate a composite image;
Combining images captured multiple times and overlaying the images,
The method of claim 17, further comprising the step of combining images selected from the group consisting of: The navigation route is
A human controls and positions the inspection system within the same type of turbine along the selected navigation path and records the navigation path for subsequent iterations by the inspection scope control system;
Along the selected navigation path, a human controlled and simulated positioning of the virtual inspection system within the same type of virtual turbine and recording the navigation path for subsequent iterations by the inspection scope control system;
Simulating positioning of the same type of virtual inspection scope and virtual generator along the simulated selected navigation path without human intervention and recording the navigation path for subsequent iterations by the inspection scope control system;
The method of claim 14, wherein the method is specified by a method selected from the group consisting of: The turbine is a gas turbine;
During the attaching step, the substrate is connected to a combustor inspection port;
15. The method of claim 14, wherein during the step of inspecting, the captured image is selected from the group consisting of internal components, turbine section internal components, row 1 vanes and row 1 blades. .

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